Thermal imaging camera

ABSTRACT

A thermal imaging camera having improved durability and ergonomic features including generally a seamless housing encompassing a thermal imaging core, a first handle, and a battery compartment. The housing is preferably positioned at a first end of the first handle and the battery compartment is positioned at the opposite end of the first handle. By positioning the first handle intermediate between the housing and the battery compartment, the center of gravity of the thermal imaging camera coincides generally with the handle when the thermal imaging camera is in use, that is when batteries are present within the battery compartment. The camera can also include a second handle positioned between the housing and the battery compartment, the second handle is preferably oriented generally parallel to and spaced apart from the first handle to facilitate passing of the thermal imaging camera between users. The camera also has improved water resistance, shock-resistance and other operational features.

FIELD OF THE INVENTION

[0001] The present invention relates to thermal imaging cameras and,especially, to thermal imaging cameras having improved durability andergonomic features.

BACKGROUND OF THE INVENTION

[0002] Thermal imaging cameras (“TICs”)are a relatively new tool used,for example, by firefighters and other safety personnel to provide theability to see heat sources in situations of limited visibility (forexample in heavy smoke or darkness). Thermal imaging cameras find use inmany scenarios including, but not limited to, executing search andrescue missions, assessing fire scenes, locating the seat of fires,determining the size and location of hot spots, identifying potentialflashover situations, determining entry and ventilation points,evaluating hazardous material situations, providing an incident command“eye in the sky”, providing vehicle navigation, preplanning fire codeinspections and assisting law enforcement officers.

[0003] Many thermal imaging cameras use ferroelectric thermal imaging.Ferroelectric cameras are solid-state infrared imagers that measurechanges in heat by sensing changes in capacitance. The focal planeincludes a plurality of small ceramic pixels that are made of sensingmaterials such as barium strontium titanate. An example of such a camerais the Argus 2 TIC sold by MSA and shown in MSA Bulletin No. 0119-23(1999).

[0004] Pyroelectric vidicon tube cameras also detect changes incapacitance. Because the capacitance of a fixed scene on the focal planedoes not change, the visible scene temperature must be artificiallymanipulated to generate an image in the case of pyroelectric andferroelectric cameras. In such cameras, the blades of a chopper pass infront of the detector and effectively change the scene temperature witheach pass. Each pass of a chopper blade causes a change in capacitanceand allows the detector to see an infrared image. Examples ofpyroelectric vidicon tube cameras are the Argus TIC and the Argus PlusTIC, previously sold by MSA and shown in MSA Bulletin Nos. 0105-16(1997) and 0105-16 (1998), respectively.

[0005] Recently, microbolometers have been used in thermal imagingcameras. A microbolometer thermal detector is a sensor that measureschanges in heat and infrared energy. It measures heat by sensing thechanges in resistance of each pixel in the focal plane. Themicrobolometer detector is constructed of an array of pixels that aremade of sensing materials such as vanadium oxide. Pixel resistancechanges are directly related to temperature and allow the camera toproduce an infrared image without the use of a chopper as is requiredwith pyroelectric and ferroelectric cameras.

[0006] Because of the harsh conditions in which thermal imaging camerasare used, such cameras are preferably very durable. In the case ofthermal imaging cameras used by firefighters, for example, the camerascan be exposed to extremely high temperatures as well as very wetconditions. Moreover, these cameras must also be adapted to dissipateany excess heat generated inside the camera due to its internalelectronics. Although thermal imaging cameras should be durable, theyshould also be suitable for use by individuals having somewhat limitedmobility and dexterity. In that regard, firefighters are equipped withprotective clothing, including thick gloves, that limit their ability toaccomplish certain tasks. Currently available thermal imaging camerassatisfy the above criteria to differing degrees. It, therefore, remainsvery desirable to develop thermal imaging cameras having improvedergonomics and durability.

SUMMARY OF THE INVENTION

[0007] The present invention provides a thermal imaging camera includinggenerally a housing encompassing a thermal imaging core, a first handle,and a battery compartment. The housing is preferably positioned at afirst end of the first handle and the battery compartment is positionedat the opposite end of the first handle. By positioning the first handleintermediate between the housing and the battery compartment, the centerof gravity of the thermal imaging camera coincides generally with thehandle when the thermal imaging camera is in use (that is, whenbatteries are present within the battery compartment). The camera canalso include a second handle positioned between the housing and thebattery compartment, the second handle is preferably oriented generallyparallel to and spaced part from the first handle and facilitates thepassing of the thermal imaging camera between two users.

[0008] In another aspect, the present invention provides a thermalimaging camera including resilient material placed over or around allprojecting portions of the thermal imaging camera such that when thethermal imaging camera is contacted with a plane, the resilient materialwill first contact the plane regardless of the orientation of thethermal imaging camera relative to the plane. In other words, if thethermal imaging camera is dropped on a generally flat surface, theresilient material contacts the surface first, thereby reducing thelikelihood of damage to the camera due to the shock-absorbing propertiesof the resilient material.

[0009] In one embodiment, the thermal imaging camera includes a housingencompassing a thermal imaging core, a handle, and a batterycompartment. The housing is positioned at a first end of the handle andthe battery compartment is positioned at the opposite end of the handle.The housing has resilient material surrounding a front end thereof and arear end thereof. Likewise, a bottom portion of the battery compartmentis also surrounded by resilient material. The resilient material can bein the form of elastomeric (for example, rubber) bumpers havingshock-absorbing properties.

[0010] In another aspect, the present invention provides a thermalimaging camera including a housing encompassing a thermal imaging core,a first handle and a second handle. The first handle and the secondhandle are positioned to facilitate passing the camera between twopeople without setting the camera down. Any number of two-handleconfigurations will work including, for example, a “steering wheel”configuration with the camera located in the center and a plurality ofspokes extending from the camera to the outer handles or ring. Asdescribed above in one preferred embodiment, the first handle and thesecond handle can be positioned generally parallel to and spaced apartfrom each other and can be positioned intermediate between the housingand the battery compartment. When the first handle and the second handleare positioned generally parallel to each other, the handles arepreferably spaced at least 2.0 inches apart, more preferably at leastapproximately 2.25 inches apart, and most preferably at leastapproximately 2.5 inches apart, over the area in which the handles areto be grasped.

[0011] The present invention also provides in another aspect a thermalimaging camera including a water-resistant housing to contain the cameracomponents. The housing has only a front opening and a rear opening andis formed without a seam therein such that the seamless housing of thepresent invention has only about ¼ of the sealing surface found in otherTICs. The front opening preferably has a generally flat sealing surface;likewise, the rear opening preferably has a generally flat sealingsurface both of which significantly reduce the likelihood or waterintrusion into the housing.

[0012] In another aspect, the present invention provides a thermalimaging camera including a durable housing to contain at least oneimaging component and at least one support member to position theimaging component within the housing without attaching or connecting theimaging component to the housing. The support member preferably has anexterior formed generally in the shape of the housing and an interiorformed generally in the shape of the imaging component. The supportmember is preferably shock absorbing and/or thermally insulating. Anexample of a suitable material for the support member is a foamedpolymer. Preferably, a plurality of components comprising the cameraengine or camera core are positioned in the housing using such supportmembers.

[0013] The present invention also provides a thermal imaging cameraincluding a housing to contain at least one imaging component. Theimaging component is at least partially abutted by a thermallyinsulating and shock absorbing material positioned between the housingand the imaging component. As discussed above, the thermally insulatingand shock absorbing material can be a foamed polymer.

[0014] In another aspect, the present invention provides a thermalimaging camera including a power source that has at least a firstbattery and a second battery. The thermal imaging camera furtherincludes circuitry so that power is first drawn from one of the firstbattery and the second battery and then from the other of the firstbattery and the second battery. The first battery and the second batteryare preferably replaceable while the thermal imaging camera isoperating. For example, the first battery can be drawn down until poweris switched to the second battery. The first battery can then bereplaced during operation while the camera is being powered by thesecond battery. Later the second battery can be replaced while thecamera is being powered by the other battery and so on. In this manner,the thermal imaging camera can be operated for long periods of timewithout shutting down the camera to replace batteries.

[0015] In still a further aspect, the present invention provides athermal imaging camera including a generally flat surface thereonwhereby the thermal imaging camera can be set in an upright position ona generally flat surface. In one embodiment, the thermal imaging cameraincludes a housing encompassing a thermal imaging camera core, a batterycompartment, and at least a first handle positioned between the housingand the battery compartment. In this embodiment, the bottom of thebattery compartment is generally flat so that the thermal imaging cameracan be set in an upright position on a generally flat surface such thatthe camera display is easily visible and the image thereon is also in anupright position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a perspective view of an embodiment of a thermal imagingcamera of the present invention.

[0017]FIG. 2 is a rear elevational view of the camera shown in FIG. 1.

[0018]FIG. 3 is a front elevational view of the camera shown in FIG. 1.

[0019]FIG. 4 is a side elevational view of the camera shown in FIG. 1.The left and right side elevational views are mirror images of eachother.

[0020]FIG. 5 is a top plan view of the camera shown in FIG. 1.

[0021]FIG. 6 is a bottom plan view of the camera shown in FIG. 1.

[0022]FIG. 7 is a perspective view of the camera shown in FIG. 1 in anassembled state with identifying numbers.

[0023]FIG. 8 is a perspective view of the thermal imaging camera of FIG.7 in a disassembled state.

DETAILED DESCRIPTION OF THE INVENTION

[0024] FIGS. 1-6 show various external views of a preferred embodimentof the thermal imaging camera of the present invention. Attached heretoas Appendix 1 is the final version of the Operations and InstructionManual for the Evolution™ 4000 Thermal Imaging System, the disclosure ofwhich is incorporated herein by reference.

[0025] In the embodiment shown in FIGS. 7 and 8, thermal imaging camera10 includes a housing 20. Housing 20 can, for example, be fabricatedfrom a molded polymeric material. Preferably, housing 20 is fabricatedin a manner to provide a good seal against water entering housing 20. Inthat regard, housing 20 is preferably formed as a continuous tube orconduit without seams along the length thereof. As shown in FIG. 8,housing 20 includes a first opening 30 at the rear thereof and a secondopening 40 at the front thereof. Preferably, each of opening 30 andopening 40 are provided with a generally flat sealing surface (forexample, sealing surface 35) around the perimeter thereof. Typically,generally flat sealing surfaces are more easily and reliably sealed thana curved surface. Housing 20 can therefore be better sealed (forexample, against water damage) than is possible with currently availablethermal imaging cameras. Moreover, the length of the sealing surface ofthe housing of the present invention is about one-fourth that found incurrently available TICs.

[0026] Housing 20 encloses a thermal imaging camera core 100 which is anassembly of camera components that preferably includes imagingcomponents such as a microbolometer thermal detector as described above.An example of a suitable camera core 100 for use in the presentinvention is the Uncooled Infrared Imaging Module, SIM 200S w/Lensavailable from Sanders, a British Aerospace company, located inLexington, Mass. That camera core includes an uncooled microbolometerfocal plane array assembly; a focal plane front end printed circuitboard assembly (PCBA); a video signal processor PCBA; a powersupply/shutter drive PCBA; a shutter drive; a lens assembly and amounting. Camera core 100 preferably also includes a heat sink 110 toabsorb heat generated internal to the camera 10. Heat sink 110 can, forexample, include an aluminum housing that is filled with a phase changematerial such as the ComforTemp® material available from FrisbyTechnologies of Winstom-Salem, N.C.

[0027] Camera core 100 can also include a remote transmitter 120 (forexample, an RF transmitter operating at 2.4 Giga Hertz) having anantenna 130 to transmit video produced by camera 10 to a remotereceiver/monitor (not shown). A suitable transmitter for use in thepresent invention is the Minilink 2.4TA transmitter available fromMicroTek Electronics, Inc. of Sam Clemente, Calif.

[0028] Camera core 100 is preferably held in place within housing 20 by,for example, support members 200 a and 200 b. The exterior profile ofsupport members 200 a and 200 b preferably conforms generally to theshape of the inner wall of housing 20 while the interior profile ofsupport members 200 a and 200 b conform generally to the shape of cameracore 100. Such support members are preferably fabricated from athermally insulating and shock absorbing material such as a foamedpolymeric material. An example of a suitable foamed polymeric materialfor support members 200 a and 200 b is E-PAC, an expanded polypropylenefoam, available from Tuscarora Incorporated of New Brighton,Pennsylvania. E-PAC is described in E-PAC: Electronic Packaging AssemblyConcept available from Tuscarora Incorporated atwww.tuscarora.com/epac.htm, the disclosure of which is incorporatedherein by reference. Use of support members 200 a and 200 b instead ofrigidly mounting or connecting camera core 100 to housing 20 allows forsimple, quick and relatively inexpensive assembly. Moreover, use ofsupport members such as support member 200 a and 200 b have been foundto improve the thermal resistance and shock resistance of thermalimaging camera 10 as compared to currently available thermal imagingcameras. Preferably, support members for use in the present inventionhave a thermal conductivity in the range of approximately 0.01BTU/ft-hr.-° F. to approximately 1.0 BTU/ft-hr.-° F. Such materials canalso be shock absorbing by, for example, being compressible orresilient.

[0029] Camera 10 also includes a display 300 such as an LCD display asknown in the art in communication with camera core 100. As described forcamera core 100, display 300 is preferably held in place within housing20 by a support member 200 c of the type discussed above. The exteriorperimeter or profile of support member 200 c preferably generallyconforms to the shape of housing 20 while the interior profile thereofgenerally conforms to display 300.

[0030] In general, thermal imaging cameras are operated over a widerange of thermal conditions including, for example, at subfreezingtemperatures, at room temperature, and at the highly elevatedtemperatures experienced by firefighters at a fire scene. Manyelectronic components are adversely affected by extreme temperatures.The thermally insulating nature of the support members of the presentinvention enable camera 10 to be operated for extended period of timesat elevated temperatures and at subfreezing temperatures.

[0031] A number of the components of camera 10 generate heat duringoperation. This presents a problem at elevated temperatures. These heatgenerating components include, for example, components having processorssuch as camera core 100 and display 300. Care must be taken to not trapsuch internally generated heat within camera 10 such that failuresoccur, even at ambient temperature. For this reason, support members 200a-c are preferably designed to insulate the internal components ofcamera 10 from high external or ambient temperatures while, at the sametime, allowing heat generated by these components within camera 10 todissipate at lower ambient temperatures. For example, support member 200c is preferably designed with a profile that is deeper (in thelongitudinal direction of housing 20, that is, front-to-back) thandisplay 300. This dimensioning of support member 200 c creates a voidbehind display 300 into which heat generated by display 300 can bedissipated. Moreover, support members 200 a and 200 b are preferablyformed with one or more open areas such as areas 205 a, 205 b, 210 a and210 b through which heat generated within camera core 100 can bedissipated. The design of support members 200 a and 200 c are preferablyoptimized to allow dissipation of internally generated heat at ambienttemperature and above while protecting the components within housing 20from external heat at elevated temperatures high above ambienttemperature. Because of the many different types of electricalcomponents that can be used within the thermal imaging cameras of thepresent invention (and the widely varying heat generating anddissipating properties of such components), such optimization ispreferably readily performed empirically. For example, the temperatureat various points within camera 10 can be measured for various supportmember designs and for various temperatures.

[0032] Front opening 30 is preferably enclosed and sealed via, forexample, a clear polycarbonate window 400 and an intermediate gasket 410that cooperates with generally flat sealing surface 35 to produce asubstantially waterproof seal. A cover lens 420 can be provided overpolycarbonate window 400. A resilient bumper 430 (for example, a rubberbumper) is preferably provided to surround the perimeter of frontopening 30 of housing 20. Resilient bumper 430 assists in absorbing theshock of an impact if the camera 10 is dropped or bumped.

[0033] A germanium window 500 is preferably provided on the front end ofcamera 10. Front opening 40 is preferably sealed by a front plate 510and an intermediate gasket 520 that cooperates with a generally flatsealing surface (not shown) of opening 40. Front plate 510 also seatsgermanium window 500. The front end of camera 10 is preferably providedwith a resilient bumper 530. Like resilient bumper 430, resilient bumper530 assists in absorbing the shock of an impact in the event that thecamera 10 is dropped or bumped.

[0034] A handle assembly 600 is preferably attached to the bottom ofhousing 20. Handle assembly 600 preferably forms a first handle 610 anda second handle 620 (as best illustrated in FIG. 7). Generallyvertically oriented handles 610 and 620 are preferably spacedsufficiently far apart to facilitate passing of thermal imaging camera10 from one firefighter to another even while wearing gloves. In thecase of generally parallel handles 610 and 620, the handles arepreferably spaced at least 2.0 inches apart, more preferably at leastapproximately 2.25 inches apart, and most preferably at leastapproximately 2.5 inches apart, over the area in which handles 610 and620 are to be grasped by users. Rear handle 610 is used when operatingcamera 10 while forward handle 620 is used to pass the camera (in anupright position) to another person.

[0035] A battery compartment 700 is preferably formed at the bottom ofhandle assembly 600. Preferably, battery unit 710 and batteries 712 and714 are easily insertable in and removable from battery compartment 700even by a user wearing heavy protective gloves. In the embodiment shownin FIG. 8, for example, battery compartment 700 includes a bracket 720that retains batteries 712 and 714 (via groove 715) within batterycompartment 700. Bracket 720 is preferably rotatable out of alignmentwith battery unit 710 to insert or remove batteries 712 and 714.Preferably, camera 10 is provided with multiple batteries that are hotswappable. For example, two batteries 712 and 714 can be used serially.In that regard, circuitry is provided so that one battery is used beforethe second battery. The used battery can preferably be replaced whilethe second battery is in service without interrupting operation ofcamera 10.

[0036] The bottom of battery compartment 700 is preferably surrounded bya resilient bumper 730 (for example, rubber) to assist in absorbing theshock of an impact if the camera 10 is dropped or bumped. Resilientbumpers 430, 530 and 730 cover all the extremities or projectingportions of camera 10 such that if camera 10 is dropped on a flatsurface or plane, one of the resilient bumpers will always first contactthe surface or plane regardless of the orientation of camera 10.

[0037] By placing housing 20 above handle 610 and battery compartment700 below handle 610, the center of gravity of camera 10 coincidesgenerally with the location at which the user holds camera 10. Becausethe center, of gravity of camera 10 coincides with the user's grip, thecamera feels lighter and more balanced than currently available camerasof similar weight. Typically, such cameras place the housing, imagingcomponents and power source above the handle.

[0038] The bottom of camera 10 is preferably generally flat so thatcamera 10 can be set upright on a generally flat surface for use withoutthe requirement of a user holding camera 10. In that regard, the bottomsurface of resilient bumper 730 is preferably generally flat. Camera 10can thus be operated/viewed in an upright position by a user without theuser having to hold camera 10. To facilitate such operation (and generaloperation), display 300 is preferably larger than is the case with priorthermal imaging cameras. In one embodiment of the present invention, forexample, display 300 had a diagonal measurement of approximately fiveinches.

[0039] Although the present invention has been described in detail inconnection with the above examples, it is to be understood that suchdetail is solely for that purpose and that variations can be made bythose skilled in the art without departing from the spirit of theinvention except as it may be limited by the following claims.

What is claimed is:
 1. A thermal imaging camera comprising: a housingencompassing a camera core, a first handle, and a battery compartment,the housing positioned at a first end of the first handle and thebattery compartment positioned at the opposite end of the first handlesuch that the center of gravity of the thermal imaging camera coincidesgenerally with the handle when the thermal imaging camera is in use. 2.The camera of claim 1 further comprising a second handle positionedbetween the housing and the battery compartment, the second handle beingoriented generally parallel to the first handle.
 3. A thermal imagingcamera comprising resilient material placed over all projecting portionsof the thermal imaging camera such that when the thermal imaging camerais contacted with a plane, the resilient material will first contact theplane regardless of the orientation of the thermal imaging camerarelative to the plane.
 4. The thermal imaging camera of claim 3 whereinthe thermal imaging camera includes a housing encompassing a cameracore, a handle, and a battery compartment, the housing positioned at afirst end of the handle and the battery compartment positioned at theopposite end of the handle, the housing having resilient materialsurrounding a front end thereof and a rear end thereof, a bottom portionof the battery compartment also being surrounded by resilient material.5. A thermal imaging camera comprising: a housing encompassing a cameracore, a first handle and a second handle, the first handle and thesecond handle being positioned to facilitate passing the camera betweentwo people without setting the camera down.
 6. The thermal imagingcamera of claim 5 wherein the first handle and the second handle arepositioned generally parallel to each other.
 7. The thermal imagingcamera of claim 6 further including a battery compartment, the firsthandle and the second handle being positioned intermediate between thehousing and the battery compartment.
 8. The thermal imaging camera ofclaim 3 wherein the first handle and the second handle are spaced atleast 2.0 inches apart over the area in which the first handle and thesecond handle are to be grasped.
 9. A thermal imaging camera comprising:a housing containing a camera core, the housing having a front openingand a rear opening, the housing being formed without a seam therein, thefront opening having a generally flat sealing surface, the rear openinghaving a generally flat sealing surface.
 10. A thermal imaging cameracomprising: a housing containing at least one imaging component and atleast one support member to position the imaging component within thehousing without attaching the imaging component to the housing, thesupport member having an exterior side formed generally in the shape ofthe housing and an interior side formed generally in the shape of theimaging component.
 11. The thermal imaging camera of claim 10 whereinthe support member is shock absorbing.
 12. The thermal imaging camera ofclaim 10 wherein the support member is thermally insulating.
 13. Thethermal imaging camera of claim 10 wherein the support member isfabricated from a foamed polymer.
 14. A thermal imaging cameracomprising: a housing containing at least one imaging component, theimaging component being at least partially abutted by a thermallyinsulating and shock absorbing material positioned between the housingand the imaging component.
 15. The thermal imaging camera of claim 14wherein the thermally insulating and shock absorbing material is afoamed polymer.
 16. A thermal imaging camera comprising: a power source,the power source including at least a first battery and a secondbattery, the thermal imaging camera further comprising circuitry so thatpower is first drawn from one of the first battery and the secondbattery and then from the other of the first battery and the secondbattery, the first battery and the second battery being replaceablewhile the thermal imaging camera is operating.
 17. A thermal imagingcamera having a generally flat surface thereon whereby the thermalimaging camera can be set in an upright position on the generally flatsurface.
 18. The thermal imaging camera of claim 17 further comprising:a housing encompassing a camera core, a battery compartment, and atleast a first handle positioned between the housing and the batterycompartment, the bottom of the battery compartment being generally flatso that the thermal imaging camera can be set in an upright position ona generally flat surface.